ATV250 02 (PP e marmitta) .pdf



Nom original: ATV250-02 (PP e marmitta).pdf

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2. FRAME COVERS/EXHAUST MUFFLER

Mongoose/KXR 250

2
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2

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FRAME COVERS/EXHAUST MUFFLER
__________________________________________________________________________________

SERVICE INFORMATION -------------------------------------------TROUBLESHOOTING ------------------------------------------------FRAME COVERS ------------------------------------------------------EXHAUST MUFFLER REMOVAL -----------------------------------

2- 2
2- 2
2- 3
2- 7

2-0

2. FRAME COVERS/EXHAUST MUFFLER

2-1

Mongoose/KXR 250

2. FRAME COVERS/EXHAUST MUFFLER

Mongoose/KXR 250

SERVICE INFORMATION
GENERAL INSTRUCTIONS
• When removing frame covers, use special care not to pull them by force because the cover joint
claws may be damaged.
• Make sure to route cables and harnesses according to the Cable & Harness Routing.
TORQUE VALUES
Exhaust muffler lock bolt
Exhaust muffler lock nut

3.2_ 3.8kgf-m
1.8_ 2.2kgf-m

TROUBLESHOOTING
Noisy exhaust muffler
• Damaged exhaust muffler
• Exhaust muffler joint air leaks
Lack of power
• Caved exhaust muffler
• Exhaust muffler air leaks
• Clogged exhaust muffler

2-2

2. FRAME COVERS/EXHAUST MUFFLER

Mongoose/KXR 250

FRAME COVERS

Seat

Lever

SEAT REMOVAL
Pull the lever right and pull up the seat at
the rear.
Remove the seat.

LEFT/RIGHT FRAME COVER
REMOVAL
Remove the seat. (See page 2-3)

Frame Left Cover

Bolts

Remove the screw and two bolts at the left
frame cover, then remove left frame cover.

Screw

Remove the screw and two bolts at the right
frame cover, then remove right frame cover.

Bolts

Frame Right Cover

°ØDuring removal, do not pull the joint
claws forcedly to avoid damage.

REAR FENDER REMOVAL
Remove seat. (See page 2-3)
Remove right and left frame cover. (See page
2-3)
Remove battery. (See page 16-4)

Screw
Fuse Box

Screw and Holder

Remove the fuse box.
Remove the screw attaching the ignition
unit/change gear control unit/starter relay
holder and remove holder.

Battery

2-3

2. FRAME COVERS/EXHAUST MUFFLER

Bolts

Remove the three bolts at the rear fender.

Screws

Remove the two screws attaching the right
and left floor board.

Remove the two screws attaching the frame
body and three screws attaching the outlet
hose, then remove the rear fender.

Mongoose/KXR 250

Screws

Screws

°ØDuring removal, do not pull the joint
claws forcedly to avoid damage.

Outlet Hose

HANDLEBAR COVER REMOVAL
Remove the two screws at the handlebar
cover.
Disconnect the indicator lamp coupler, then
remove the handlebar cover.

Screws

Indicator Lamp coupler

2-4

2. FRAME COVERS/EXHAUST MUFFLER

Mongoose/KXR 250
Bolts

CENTER FRAME COVER REMOVAL
Remove the seat. (See page 2-3)
Remove the fuel fill cap.
Remove the four bolts at the center frame
cover, then remove the center frame cover.

°ØAfter remove, be sure to tighten the fuel
fill cap.

Fuel Fill Cap

FRONT FENDER REMOVAL
Remove the seat (See page 2-3), right and
left side frame cover (See page 2-3) and
center frame cover. (See page 2-5)

Bolts

Remove the two bolts at the front fender
left side.
Remove the two screws attaching the inlet
hose.

Screws

Remove the two bolts at the front fender
right side.

Bolts

Remove the screw, then remove the drive
select grip from the drive select lever.

2-5

Screw

Select Grip

2. FRAME COVERS/EXHAUST MUFFLER

Mongoose/KXR 250

Disconnect headlight and ignition switch
couplers, then remove the front fender.

Ignition Coupler

Headlight Coupler

RIGHT AND LEFT FLOOR BOARD
REMOVAL
Remove the four screws at the floor board,
then remove the floor board.

Screws

FRONT CARRIER REMOVAL
Remove the four bolts at the front carrier,
then remove the front carrier.

Bolts

2-6

2. FRAME COVERS/EXHAUST MUFFLER

Mongoose/KXR 250

EXHAUST MUFFLER
REMOVAL
Remove the two exhaust pipe joint lock
nuts.
Remove the bolt at the exhaust muffler,
disconnect the exhaust pipe from the
exhaust muffler.

Nuts

Bolt
Gasket

Inspect the gasket.
If the exhaust gas leaks, the gasket should be
replaced.
Install by reversing the removal sequence.
Torque:
Exhaust muffler lock bolt: 3.2_ 3.8kgf-m
Exhaust muffler lock nut: 1.8_ 2.2kgf-m

°ØBe sure to install a new exhaust gasket.
Nut

Remove the nut and bolt at the exhaust
muffler, then remove the exhaust muffler.

Bolt

INSTALLATION
Install by reversing the removal sequence.
Torque:
Exhaust muffler lock bolt and nut:
3.2_ 3.8kgf-m

2-7


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